CUMMINS HQD 810 HQDSA-810 Installation guide

Installation Manual

Hybrid Quiet Diesel Power System HQDSA

Power Unit HQDPC

Inverter Charger HQDVA

Transfer Switch HQDTA

English 05−2008 981−0645 (Issue 3)

California

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

diesel warnings

i

Table of Contents

SAFETY PRECAUTIONS iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About The Hybrid Power System 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Codes and Standards for Safety 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. POWER UNIT INSTALLATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outline Drawing 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosure 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling and Ventilation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Connections 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Connections 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Connections 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Communications Connections 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Connections 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. INVERTER/CHARGER INSTALLATION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location, Mounting and Enclosure 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Connections 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TRANSFER SWITCH INSTALLATION 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. ACCESSORY KIT INSTALLATIONS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shunt/Fuse Block 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. AC CONNECTIONS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Wire Strip Lengths and Terminal Torques 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shore Power Fuses 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shore Pass-Through Circuits 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

Connections at Transfer Switch 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections at Inverter/Charger 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections at Power Unit 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. COMMUNICATIONS AND INPUT CABLES 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Unit Connections 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Demand Input 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Safety Input 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Saver Signal 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shunt Input 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Temperature Sensor 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. COACH BATTERY INSTALLATION 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Type 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Enclosure 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Voltage 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Capacity 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Coach Batteries 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. COACH BATTERY CONNECTIONS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inverter/Charger Connections 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Unit Connections 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DC Load Connections and Disconnect Switch 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. INSTALLATION REVIEW AND STARTUP 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Review 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 10-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX A. OPERATOR PANEL A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About the Operator Panel A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Home Screen A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO Button A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clock Button A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Button A-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status Menu A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batt Status A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Status A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gen Status A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

Inv Status A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shore Status A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Information A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Menu A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Setup A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shore Breaker A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Setup A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Menu A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Setup A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Setup A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equalize A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About A-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning and Prompt Screens A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX B. BATTERY INTERCONNECTIONS B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX C. HOT AIR RECIRCULATION TEST C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX D. SPECIFICATIONS D-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX E. OUTLINE AND SYSTEM DRAWINGS E-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv

SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL

before operating the Hybrid Quiet Diesel Pow-

er System (Hybrid Power System). Safe opera-

tion and top performance can only be obtained

when equipment is properly operated and

maintained.

The following symbols in this manual alert you to

potential hazards to the operator, service person

and equipment.

DANGER

alerts you to an immediate hazard

that will result in severe personal injury or

death.

WARNING

alerts you to a hazard or unsafe

practice that can result in severe personal in-

jury or death.

CAUTION

alerts you to a hazard or unsafe

practice that can result in personal injury or

equipment damage.

For quick reference the potential hazards of this

type of equipment and the precautions to take are

listed below in this section.

GENERAL PRECAUTIONS

• Keep children away from Hybrid Power Sys-

tem components.

• Do not use evaporative starting fluids. They

are highly explosive.

• Let the engine cool down before removing

the coolant pressure cap or opening the cool-

ant drain. Releasing hot coolant under pres-

sure can lead to severe burns.

• Keep the Hybrid Power System components

and their enclosures clean. Oil collects dirt

that can restrict cooling. Oily rags can catch

fire. Stowed gear can block cooling air.

• Make sure all fasteners are secure and

torqued properly.

• Do not perform Hybrid Power System mainte-

nance or service when mentally or physically

tired or after consuming alcohol or drugs.

• You must be trained and experienced to

make adjustments while the Hybrid Power

System is in operation—hot, moving or elec-

trically live parts can cause severe personal

injury or death.

• Used engine oil has been identified by some

U. S. state and federal agencies as causing

cancer or reproductive toxicity. Do not ingest,

inhale, or contact used oil or its vapors.

• Ethylene glycol, used as engine antifreeze, is

toxic to humans and animals. Clean up spills

and dispose of used engine coolant in accor-

dance with local environmental regulations.

• Keep a multi-class ABC fire extinguisher in

the vehicle. Class A fires involve ordinary

combustible materials such as wood and

cloth. Class B fires involve combustible and

flammable liquids and gaseous fuels.

Class C fires involve live electrical equip-

ment. (ref. NFPA No. 10)

• The Hybrid Power System installation must

comply with all applicable local, state and fed-

eral codes and regulations.

v

ENGINE EXHAUST IS DEADLY

Engine exhaust gases include CARBON MON-

OXIDE (CO), an odorless, colorless, poisonous

gas that can cause severe personal injury or

death. Symptoms of CO poisoning include:

• Dizziness, Headache or Throbbing Temples

• Weakness or Muscular Twitching

• Sleepiness or Confusion

• Nausea or Vomiting

If you or anyone else experiences any of these

symptoms, get out into fresh air immediately. Get

advice from 911, poison control or a medical cen-

ter. Do not enable AUTO or start Generator Mode

until the exhaust system has been repaired.

To reduce the risk of CO poisoning from engine

exhaust:

• Check for exhaust leaks every day and after

every eight hours of operation.

• Do not enable AUTO or start Generator Mode

before going to sleep unless the coach has

working CO detectors.

• Disable AUTO and stop Generator Mode

when parking the coach in a garage or other

confined space.

• Do not use engine cooling air to heat the

coach. It may contain exhaust gases.

• The exhaust system must be installed in ac-

cordance with the Hybrid Power System

Installation Manual.

POWER SYSTEM VOLTAGES ARE

DEADLY

• Before servicing the coach or Hybrid Power

System, disconnect Shore Power, push the

Power Unit circuit breaker OFF and turn the

Coach DC Disconnect Switch to Disconnect

(to power down the Hybrid Power System).

• Electrical connections must be made by a

trained and experienced electrician in accor-

dance with the Hybrid Power System Installa-

tion Manual and applicable codes.

• Do not connect the Power Unit to the Coach

AC circuits. Its high output voltages can dam-

age equipment and cause death or severe

personal injury.

• Improper transfer of loads between the Hy-

brid Power System and Shore Power can

lead to electrocution of utility line workers and

damage to equipment. Connections must be

made by a trained and experienced electri-

cian in accordance with the Hybrid Power

System Installation Manual and applicable

codes.

• Use caution when working on live electrical

equipment. Remove jewelry, make sure

clothing and shoes are dry, stand on a dry

wooden platform or rubber insulating mat and

use tools with insulated handles.

• Upon completing service, secure housing

panels and covers to protect from electrical

parts.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

• Disconnect the 10-Pin and 4-Pin remote con-

trol connectors and battery cables from the

Power Unit to prevent unintended starting

while servicing. Insulate the end of the posi-

tive (+) battery cable to keep it from touching

chassis ground.

• Keep hands away from fans, belts, pulleys

and other moving parts.

• Remove loose clothing and jewelry.

• Upon completing service, secure housing

panels and covers to protect from moving

parts.

vi

BATTERY GAS IS EXPLOSIVE

• Before servicing the batteries, disconnect

Shore Power, push the Power Unit circuit

breaker OFF and turn the Coach DC Discon-

nect Switch to Disconnect (to power down the

Hybrid Power System).

• Wear safety glasses.

• Do not smoke.

• Remove jewelry.

• Observe proper battery cable connect/dis-

connect sequences.

• Secure DC terminal protective covers to pre-

vent accidental shorting with metal tools.

IMPROPER CHARGING CAN OVERHEAT

COACH BATTERIES AND CAUSE FIRE

Do not mix old and new batteries or different types

of batteries. Reconfigure the Hybrid Power Sys-

tem for proper charging if battery type and bank

capacity have changed.

DIESEL FUEL IS COMBUSTIBLE

• Do not smoke or turn electrical switches ON

or OFF where fuel fumes are present or in

areas sharing ventilation with fuel tanks or

equipment. Keep flames, sparks, pilot lights,

arc-producing equipment and all other

sources of ignition well away.

• Fuel lines must be secured, free of leaks and

separated or shielded from electrical wiring.

COACH ELECTRICAL SYSTEMS CAN

IGNITE FLAMMABLE VAPORS

• Disable AUTO and stop Generator Mode be-

fore fueling the coach to reduce the risk of ig-

niting flammable vapors.

• Do not store liquid or gaseous fuel containers

in the same enclosures as the Inverter/Char-

gers, Transfer Switch, batteries or other

spark-producing equipment.

FLAMMABLE VAPORS CAN CAUSE

DIESEL ENGINES TO OVERSPEED

Do not operate the diesel-powered Hybrid Power

System where there are or can be flammable va-

pors created by fuel spills, gas leaks, etc. Flam-

mable vapors drawn into a diesel engine air intake

system can cause the engine to overspeed, which

can result in fire, explosion and equipment dam-

age. The owners and operators of the Hybrid

Power System are solely responsible for safe op-

eration.

Mobile-9

1-1

1. Introduction

ABOUT THIS MANUAL

WARNING

Improper installation can result in

severe personal injury, death and equipment

damage. The installer must be qualified to per-

form the installation of electrical and mechani-

cal equipment.

This is the installation manual for the Model HQDSA

Hybrid Quiet Diesel Power System (Hybrid Power

System), comprising:

• Model HQDPC Power Unit

• Model HQDVA Inverter/Charger

• Model HQDTA Transfer Switch

• Accessory Kits

For specific information about the system and its

components, see Appendix D. Specifications.

Note: The Hybrid Power System will not work without

these components, nor with substitutes.

Proper installation is essential for top performance,

safety and compliance. Read through this manual

before starting the installation.

See the Operator’s Manual for operation and main-

tenance instructions.

Note: Manuals are updated from time to time to re-

flect changes in the equipment and its specifica-

tions. See an authorized Cummins Onan representa-

tive for current manuals.

ABOUT THE HYBRID POWER SYSTEM

WARNING

This power system is not for life

support. It can stop without warning. Children,

persons with physical or mental limitations, and

pets could suffer personal injury or death. A per-

sonal attendant, redundant power or an alarm

system must be used if operation is critical.

The Hybrid Power System components are inte-

grated with Shore Power and Coach Batteries to

comprise a complete Coach AC power supply sys-

tem. The Operator Panel is used to monitor, control

and configure the integrated power supply system.

CAUTION

Unauthorized modifications or re-

placement of fuel, exhaust, air intake or speed

control system components that affect engine

emissions are prohibited by law in the State of

California.

1-2

INSTALLATION CODES AND STANDARDS

FOR SAFETY

The installer bears sole responsibility for the selec-

tion of appropriate equipment, for its proper installa-

tion and for obtaining approvals from the authorities

(if any) having jurisdiction over the installation. The

Hybrid Power System is suitable for installation in

accordance with:

• NFPA No. 1192—Recreational Vehicles

• NFPA No. 70, Article 551—Recreational Ve-

hicles and RV Parks

• ANSI/RVIA-12V—Standard for Low Voltage

Systems in Conversion and Recreational Ve-

hicles

Federal, State and local codes, such as the Califor-

nia Administrative Code—Title 25 (RV installation),

could apply. Installation codes and recommenda-

tions can change from time to time and are different

in different countries, states and municipalities. It is

recommended that the standards in Table 1-1 be

obtained for reference.

TABLE 1-1. REFERENCE CODES AND STANDARDS

Code of Federal

Regulations,

Title 49: Chapter III

and Chapter V

Superintendent of Documents

P. O. Box 371954

Pittsburgh, PA 15250-7954

NFPA No 70, 1192

National Fire Protection Association

470 Atlantic Avenue

Boston, MA 02210

ANSI/RVIA-12V

Recreational Vehicle Industry Association

14650 Lee Road

Chantily, VA 22021

California Adminis-

trative Code—Title

25, Chapter 3

State of California Documents Section

P.O. Box 1015

North Highlands, CA 95660

CAN/CSA-Z240

Recreational

Vehicles &

CSA C22.1, Part 1

Canadian Electric

Code

Canadian Standards Association

Housing and Construction Materials Section

178 Rexdale Blvd.

Rexdale, Ontario, Canada M9W 1R3

UL 1248, 458,

1008, 1004B

Underwriters Laboratories Inc

333 Pfingsten Road

Northbrook, IL 60062

2-1

2. Power Unit Installation

OUTLINE DRAWING

Refer to the Power Unit Outline Drawing (p. E-3) for

installation details: mounting bolt hole locations,

connection points (fuel, battery, exhaust, coolant,

remote control, AC output), sizes and types of fit-

tings, cooling air openings, weight, service access

points and overall dimensions. See your Onan deal-

er for a large-scale Outline Drawing and full-size

floor cutout template.

MOUNTING

WARNING

The Power Unit support structure

must be designed and installed to support and

restrain the dynamic weight of the Power Unit.

Failure to do so can result in the Power Unit

dropping onto the roadway causing property

damage, severe personal injury and death.

Supporting Structure

Support the Power Unit on a structure able to resist

the dynamic weight of the Power Unit. Dynamic ver-

tical weight (up and down) is defined as 3 times stat-

ic weight and dynamic horizontal weight is defined

as 1 times static weight. The power unit has a static

weight of 391 lbs (177 kg). Vertical dynamic weight

is therefore plus/minus 1173 lbs ( 531 kg) and hori-

zontal dynamic weight is 391 lbs (177 kg).

Mounting Hardware

The Power Unit is shipped with four 3/8-16 by 1-1/2

inch thread-forming screws to secure it to the sup-

porting frame or floor. Torque the mounting screws

to 31 lb-ft (42 N-m).

2-2

LOCATION

Typical Power Unit locations on a vehicle are illus-

trated in Figure 2-1.

1. Provide access to the control panel so that the

Power Unit can be started with the control

switch, the circuit breakers can be reset and

coolant and oil can be added.

2. Provide access underneath the Power Unit to

change the air, oil and fuel filters and drain oil

and coolant. The oil and fuel filter access door

must be able to swing wide open. See PE-

RIODIC MAINTENANCE in the Operator’s

Manual.

3. Provide access for connecting and disconnect-

ing fuel lines, battery cables, remote control

wiring and AC wiring.

4. Make sure that frame cross members, exhaust

tail pipes and other equipment do not cross un-

derneath the oil drain plug or air intake and dis-

charge openings or the oil and fuel filter access

door.

5. Provide access for removing the two fuel pump

mounting screws so that the Power Unit does

not have to be removed to replace the fuel

pump.

6. Make sure the Power Unit clears the ground by

at least 12 inches (305 mm) to provide ade-

quate ventilation and reduce the amount of

dust pulled in by the cooling fan.

7. The Power Unit must be located so that the inlet

to the Power Unit is protected from direct expo-

sure to rain and road splash. Compliance with

this protection requirement for road splash is

assumed whenever no line of sight can be pro-

jected from the Coach tire’s contact with the

road into the inlet of the Power Unit. Consider-

ation may also need to be given to splash from

vehicles sharing the road with the Coach. It is

generally preferable to mount the Power Unit in

front of, rather than behind, the Coach tires.

8. Locate or shield the Power Unit such that con-

densate from air conditioners will not drip on it.

FIGURE 2-1. TYPICAL POWER UNIT LOCATIONS

2-3

ENCLOSURE

1. Provide a vapor and fire resistant barrier be-

tween the Power Unit and the interior of the ve-

hicle. Use approved materials (26 gauge gal-

vanized steel). See NFPA 1192 for details.

WARNING

EXHAUST GAS IS DEADLY.

Construct a suitable vapor barrier of ap-

proved materials between the Power Unit

and vehicle interior to keep out exhaust

gas.

2. The enclosure must be large enough to provide

at least 1/2 inch (12.7 mm) clearance at the top

of the Power Unit and 1/4 inch (6.4 mm) clear-

ance at the sides. These minimum clearances

apply to the thermal or acoustic insulation with

which the compartment may be lined. Minimum

compartment dimensions are:

A. Height: 22.78 inches (578.6 mm)

B. Width: 24.73 inches (628.1 mm)

C. Length: 36.85 inches (936 mm)

3. Acoustic/thermal insulation and adhesive must

be rated as “Self-Extinguishing.” Do not line the

bottom of the compartment with insulation,

which can absorb spilled fuel and oil.

COOLING AND VENTILATION

WARNING

EXHAUST GAS IS DEADLY! Do not

duct air discharged from the Power Unit into the

vehicle.

The air intake and discharge openings are in the

bottom of the Power Unit (Figure 2-2). Unrestricted

air flow for cooling, ventilation and combustion is es-

sential for proper Power Unit performance and ser-

vice life. Refer to Appendix C. Hot Air Recirculation

Test.

If the Power Unit is installed on a floor, cut out open-

ings in the floor that are at least as large as the open-

ings in the Power Unit.

Make sure frame cross members, exhaust tail pipes

and other equipment do not cross underneath the

air intake and discharge openings. Do not block the

air inlet and outlet openings with screens, expanded

metal or the like; they restrict air flow and could

cause the Power Unit to overheat.

*

HOT AIR

DISCHARGE

COOLING, COMBUSTION &

VENTILATING AIR INLET

* COOLING AIR FOR HEAT EXCHANGER THAT COOLS

THE INVERTER/CHARGER ELECTRONICS COLD PLATE.

FIGURE 2-2. COOLING, VENTILATING AND COMBUSTION AIR FLOWS

2-4

EXHAUST CONNECTIONS

WARNING

EXHAUST GAS IS DEADLY! Keep

exhaust gases from entering the vehicle. Do not

terminate the exhaust tailpipe underneath the

vehicle or closer than specified to openings into

the vehicle or route it such that it is likely to be

damaged. Use approved materials and parts

only.

CAUTION

Modifications or replacements of

fuel, exhaust, air intake or speed control system

components that affect engine emissions are

prohibited by law in the State of California.

Muffler

The muffler is mounted inside the Power Unit hous-

ing (Figure 2-3). It has been qualified as a USDA

(Forest Service) spark arrestor. See the Power Unit

Outline Drawing for the exhaust outlet flange dimen-

sions.

A Power Unit without a properly installed and main-

tained spark arresting exhaust system can cause a

forest fire. It is illegal on federal lands. Liability for

damage, injury and warranty expense due to the

modification of the exhaust system or to the use of

unapproved parts is the responsibility of the person

performing the modification or installing the unap-

proved parts. Contact an Onan distributor for ap-

proved exhaust system parts.

MUFFLER OUTLET FLANGE

TAILPIPE CLEARANCE HOLES

(USE AN ELBOW ADAPTER)

FIGURE 2-3. EXHAUST CONNECTION AT POWER UNIT

2-5

Tailpipe

Tailpipe adapter kits are separately available. Use a

straight adapter for a tailpipe routed up from below

the Power Unit. Use an elbow adapter for a tailpipe

routed through the clearance hole in the right or

back side of the base of the Power Unit. When con-

necting and routing the tailpipe:

1. Use 1-3/8 inch ID aluminized steel tubing or

equivalent for the tailpipe. (Do not use flexible

pipe. Flexible pipe is not gas tight or durable.)

2. Secure the tailpipe or adapter flange to the muf-

fler flange with a gasket and two 5/16-18 bolts.

3. Use U-bolt muffler clamps to connect sections

of tailpipe. It is recommended that the overlap-

ping pipe be slotted as shown in Figure 2-4.

4. Use automotive-type tailpipe hangers every 2

to 3 feet (610 to 914 mm). Attach the hangers

to steel framework, not to wood or other com-

bustible material.

5. Do not terminate the tailpipe underneath the

vehicle. Extend it a minimum of 1 inch (25 mm)

beyond the perimeter of the vehicle (Figure

2-5). Support the end of the tailpipe such that

it cannot be pushed inward and up under the

skirt of the vehicle by backing up into a curb or

other obstacle.

Note: Do not terminate the tailpipe underneath a

slide-out room

(Figure 2-7), unless the bottom

of the slide-out, including skirts and moldings,

is at least 3 feet above the end of the tailpipe.

6. Do not route the tailpipe such that it will interfere

with opening the Power Unit maintenance door

or draining engine oil or coolant or restrict the

air inlet.

7. Do not route the tailpipe closer than 3 inches

(76 mm) to combustible material (wood, felt,

cotton, organic fibers, etc.) unless it is insulated

or shielded. The temperature of adjacent com-

bustible material must not exceed 194

°F

(90

°C).

8. Do not route the tail pipe near fuel lines or fuel

tanks or terminate it below or near a fuel fill

opening.

9. Do not terminate the tailpipe such that it is clos-

er than 6 inches (153 mm) to any opening into

the vehicle interior (door, window, vent). See

Figure 2-6.

3/4 INCH (19 MM)

MAXIMUM SLOT

(BOTH SIDES)

FIGURE 2-4. EXHAUST TAILPIPE CONNECTIONS

1 INCH (25 MM)

MINIMUM

LAST TAILPIPE HANGER CLOSE

TO END

FIGURE 2-5. EXHAUST TAILPIPE TERMINATION

NO OPENING INTO THE VEHICLE INTERIOR MAY BE

CLOSER THAN 6 INCHES (153 MM) TO THE END

OF THE TAIL PIPE (WITHIN SHADED AREA)

6 in

153 mm

TAILPIPE

FIGURE 2-6. MINIMUM DISTANCES TO OPENINGS

2-6

10. The tail pipe must be visible and accessible

along its entire length for inspection and re-

placement.

11. Route the tailpipe such that it will not likely be

struck when the vehicle is moving. Keep it out

of the approach and departure angles of the ve-

hicle and above the axle clearance line (Fig-

ure 2-7).

12. Do not connect Power Unit exhaust to the ve-

hicle engine exhaust system.

CAUTION

Interconnecting the engine ex-

haust systems will allow exhaust conden-

sates and soot to migrate into the engine

that is idle, causing engine damage.

13. Exhaust back pressure under full load must not

exceed 2 inches (51 mm) water column (WC)

as measured within 6 inches (154 mm) of the

muffler outlet flange.

CAUTION

Excessive back pressure can

cause loss of performance and engine dam-

age.

DEPARTUR

E ANGLE

APPROAC

H ANGLE

AXLE CLEARANCE LINE

DO NOT

TERMINATE

TAILPIPE

UNDERNEATH A

SLIDE-OUT ROOM

FIGURE 2-7. APPROACH AND DEPARTURE ANGLES AND AXLE CLEARANCE LINE

2-7

FUEL CONNECTIONS

WARNING

Diesel fuel is a combustible and can

cause severe personal injury or death. Do not

smoke or allow any flame, spark, pilot light, arc-

producing equipment, electrical switch or other

ignition source around fuel or fuel components,

or in areas sharing ventilation. Keep a type ABC

fire extinguisher handy.

Do not interconnect Power Unit and vehicle engine

fuel lines. Follow the vehicle chassis manufactur-

er’s instructions when making connections to the

vehicle engine fuel tank.

CAUTION

Either or both engines could starve

for fuel if the Power Unit and vehicle engine fuel

lines are interconnected. Always use separate

fuel lines or a separate fuel tank for the Power

Unit.

To prevent the Power Unit from running the vehicle

out of fuel, do not extend the Power Unit fuel pickup

tube down into the fuel tank as far as the pickup tube

for the vehicle engine.

Fuel lines (supply and return) must have at least a

1/4 inch (6.4 mm) ID. The Power Unit has 1/8 inch

NPT fittings for fuel supply and return.

Run the fuel line at or above the top of the fuel tank to

reduce the risk of siphoning fuel out of the tank if the

line should break. The maximum fuel pump lift is

36 inches (914 mm).

Route fuel lines away from electrical wiring and hot

engine exhaust components. Fuel lines should be

accessible for inspection and replacement, pro-

tected from damage and secured to prevent kinking,

contact with sharp edges and chafing due to vibra-

tion.

COOLANT CONNECTIONS

The liquid-cooled electronics cold plate in the Invert-

er/Charger is cooled by a heat exchanger housed in

the Power Unit. For coolant hose connections be-

tween the Inverter/Charger and Power Unit refer to

Section 3. Inverter/Charger Installation.

COMMUNICATIONS CONNECTIONS

Refer to Section 7. Communications and Input

Cables for Inverter/Charger communications and

remote control connections.

BATTERY CONNECTIONS

Refer to Section 9. Coach Battery Connections.

AC OUTPUT CONNECTIONS

Refer to Section 6. AC Connections.

This side is intended to be blank

3-1

3. Inverter/Charger Installation

LOCATION, MOUNTING AND ENCLOSURE

Refer to the Inverter/Charger Outline Drawing for di-

mensions (p. E-4).

1. The Inverter/Charger must be located close

enough to the Coach Batteries so that the bat-

tery cables do not exceed 10 ft (3 meters) in

length.

2. In order to fill and prime the Inverter/Charger

cooling system, the Inverter/Charger must not

be located more than 3 feet (1 meter) higher

than the Power Unit.

3. The Inverter/Charger must be located in an en-

closure that is dry and affords protection from

dust, rain, snow and road splash.

4. The Inverter/Charger must be isolated from

batteries, fuel tanks and other sources of flam-

mable or explosive gases.

5. The Inverter/Charger base has six mounting

holes. Four 1/4 inch (6 mm) screws must be

used to mount it to the floor, wall or roof of the

enclosure. Two mounting screws must be in

front (terminal side) and two in back.

6. When secured to a wall, the Inverter/Charger

must be level and the coolant hose fittings must

point to either side, not up or down. This is to

prevent coolant from entering the electronic

components inside the Inverter/Charger if

there is a hose leak. Figure 3-1 illustrates ac-

ceptable mounting positions and orientations.

7. There must be a minimum of 1 inch (25.4 mm)

clearance on all sides and top of the Inverter/

Charger cover and room for making wiring and

coolant hose connections.

8. The Inverter/Charger has an internal cooling

fan. Air must flow freely from left to right through

and out of the enclosure. The size and location

of the enclosure and flow of air through it must

be such that the Inverter/Charger does not

overheat and shut down during normal

operation. Refer to Appendix C. Hot Air

Recirculation Test.

CAUTION

Inadequate cooling air flow or

recirculation of warm air back into the In-

verter/Charger can result in shutdowns due

to overheating.

3-2

FLOOR MOUNT

WALL MOUNT

CEILING MOUNT

5/8 INCH COOLANT

HOSE FITTINGS

COOLING

AIR OUT

COOLING

AIR IN

FIGURE 3-1. INVERTER/CHARGER—ACCEPTABLE MOUNTING POSITIONS AND ORIENTATIONS

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CUMMINS HQD 810 HQDSA-810 Installation guide

CUMMINS HQD 810 HQDSA-810 Installation guide

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